Blade core for hockey stick and the like

ABSTRACT

A blade to be mounted to a shaft of a hockey stick or like game stick including a preformed core, a shaft receiving member and first and second preformed skins is described herein. The preformed core has distal and proximate ends, top and bottom edge portions and first and second opposite lateral faces. The top edge portion is advantageously tapered. The shaft receiving member includes lower and upper portions, first and second lateral sides. The lower portion is mounted to said proximate end of said core. The upper portion is configured and sized to receive a shaft. The core is so dimensioned that the skins define the shape of the blade. A method of making such a blade is also disclosed.

FIELD OF THE INVENTION

[0001] The present invention relates to hockey sticks or like-game sticks. More specifically, the present invention is concerned with a core for blade of a hockey or like-game stick and a method for making a blade having such a core.

BACKGROUND OF THE INVENTION

[0002] Hockey is a widely popular sport. Conventional hockey sticks and like-game sticks include a blade and a shaft. The conventional manufacture process for such sticks involves a large number of individual operations. The separate steps include cutting, planning, sanding, laminating, tapering, fitting, bonding and finishing of the various pieces that make up the sticks. This process is very labour intensive and costly.

[0003] Blade structures using interior cores are well known in the art. Such blades include an interior core which has opposed side surfaces joined with a pair of reinforced plastic layers, the length and height of which are substantially equal to the length and height of the entire finished blade. These reinforced plastic layers are laminated onto the core and are themselves covered by protective layers of wood veneers or equivalent materials.

[0004] Examples of such blade structure are disclosed in U.S. Pat. Nos. 4,013,288; 4,124,208 and 4,488,721; and in Canadian patents nos 1,047,561; 1,188,343; 1,183,883; 2,228,104 and 2,244,601.

[0005] A drawback of the prior art hockey stick blade and method for making same is the manufacturing time in making the blade. Another drawback is the fact that the interior core can only be used to make a specifically shaped blade since it dictates the finished blade dimensions.

[0006] It thus remains a need to provide a faster and less costly method for making blades mountable in a shaft of a hockey or like-game stick.

OBJECTS OF THE INVENTION

[0007] The general object of the present invention is therefore to provide an improved blade for a hockey or like-game stick and method for making same.

SUMMARY OF THE INVENTION

[0008] More specifically, in accordance with the present invention, there is provided a preformed core for a blade of a hockey stick or like game stick, said stick including a shaft, said core comprising:

[0009] distal and proximate ends, said proximate end being configured and sized to receive the shaft;

[0010] top and bottom edge portions, said top edge portion being tapered; and

[0011] first and second opposite lateral faces, said first and second lateral faces being configured and sized to respectively receive first and second preformed skins;

[0012] wherein said core is so dimensioned that the shape of the blade is defined by the shape of the first and second preformed skins.

[0013] According to another aspect of the present inveniton, there is provided a blade core assembly for a blade of a hockey stick or like game stick, said stick including a shaft, said core comprising:

[0014] a core including:

[0015] distal and proximate ends;

[0016] top and bottom edge portions, said top edge portion being tapered; and

[0017] first and second opposite lateral faces;

[0018] and

[0019] a shaft receiving member including:

[0020] upper and lower portions, said lower portion being mountable to said proximate end of said core, said upper portion configured and sized to receive the shaft;

[0021] first and second opposite lateral sides;

[0022] wherein when said shaft receiving member is mounted to said core, a) said first lateral face of said core and said first lateral side of said shaft receiving member are in the same first plane, b) said second lateral face of said core and said second lateral side of said shaft receiving member are in the same second plane; c) said first and second planes are configured and sized to respectively receive fist and second preformed skins, and d) said core is so dimensioned that the shape of the blade is defined by the shape of the first and second preformed skins.

[0023] According to a third aspect of the present invention, there is provided a blade to be mounted to a shaft of a hockey stick or like game stick, said blade comprising:

[0024] a preformed core having distal and proximate ends, top and bottom edge portions and first and second opposite lateral faces; said top edge portion being tapered;

[0025] a shaft receiving member having lower and upper portions and first and second lateral sides; said lower portion being mounted to said proximate end of said core, said upper portion being so configured and sized as to receive the shaft;

[0026] first preformed skin mounted to both said first lateral face of said core and said first lateral side of said shaft receiving member; and

[0027] second preformed skin mounted to both said second lateral face of said core and said second lateral side of said shaft receiving member; wherein said preformed skins define the shape of the blade.

[0028] According to yet another aspect of the present invention, there is provided a hockey stick or like game stick, said stick comprising:

[0029] a blade including:

[0030] a preformed core having distal and proximate ends, top and bottom edge portions and first and second opposite lateral faces; said top edge portion being tapered;

[0031] a shaft receiving member having lower and upper portions and first and second lateral sides, said lower portion being mounted to said proximate end of said core; and

[0032] first preformed skin mounted to both said first lateral face of said core and said first lateral side of said shaft receiving member; and

[0033] second preformed skin mounted to both said second lateral face of said core and said second lateral side of said shaft receiving member; wherein said preformed skins define the shape of the blade;

[0034] and

[0035] a shaft having a lower section mounted to said upper portion of said shaft receiving member.

[0036] According to a final aspect of the present invention, there is provided a method of making a blade to be mounted to a shaft of a hockey stick or like game stick, said method comprising the steps of:

[0037] (a) making a preformed core for the blade, said core having a size that is smaller than that of the blade, said core including distal and proximate ends, top and bottom edge portions, and first and second opposite lateral faces;

[0038] (b) making a shaft receiving portion including upper and lower portions and first and second opposite lateral sides;

[0039] (c) mounting said lower portion of said shaft receiving member to said proximate end of said core;

[0040] (d) making first and second preformed skins;

[0041] (e) mounting said first preformed skin to said first lateral face of said core and to said first lateral side of said shaft receiving member and mounting said second skin to said second lateral face of said core and to said second lateral side of said shaft receiving member, wherein said first and second preformed skin define the final shape of the blade.

[0042] It is to be noted that the terms “plastic” and “plastic material” are used interchangeably herein and are to be construed as including recyclable pastics such as, for example, polyethylenes and non-recyclable plastics such as, for example, thermosetting plastics obtained by reacting polyester resins.

[0043] Other objects, advantages and features of the present invention will become more apparent upon reading of the following non restrictive description of preferred embodiments thereof, given by way of example only with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] In the appended drawings, like reference numerals refer to like elements throughout and in which:

[0045]FIG. 1 is an exploded perspective view of a blade according to a preferred embodiment of the present invention;

[0046]FIG. 2 is a front view of the core and skins of the blade of FIG. 1;

[0047]FIG. 3 is a front view of the assembled core and skins of the blade of FIG. 1;

[0048]FIG. 4 is view similar to that of FIG. 3 where the blade further includes a supplemental protective layer;

[0049]FIG. 5 is a top view of a sheet of material with the cut out skins of the blade of FIG. 1;

[0050]FIG. 6 is a view similar to FIG. 2 with the skins being made of a different material;

[0051]FIG. 7 is a view similar to that of FIG. 4 with the skins being made of a different material;

[0052]FIG. 8 is a view of the core and the skins of the blade according to the present invention, with each skin being made of two pieces of different material; and

[0053]FIG. 9 is a perspective view of an assembled hockey stick or like game having a blade constructed with the core of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0054] With reference to FIGS. 1 to 5 of the appended drawings, a first preferred embodiment of the present invention will be described.

[0055]FIG. 1 shows an exploded view of a blade 10, to be mounted to a tubular hockey shaft 12 or like-game stick.

[0056] The blade 10 includes a preformed core 16, a shaft receiving member 18 and first and second preformed skins 20 and 22. It is to be understood that the terms “first” and “second” are used herein only for convenience and hence, are interchangeable.

[0057] The core 16 is shown having distal and proximate ends 24 and 26, top and bottom edge portions 28 and 30, and first and second opposite lateral faces 32 and 34 (see FIGS. 2, 3, 4 and 6). Again, the terms “first” and “second” are interchangeable.

[0058] The top edge portion 28 is tapered, the reason for which will be described hereinbelow.

[0059] Generally stated, the proximate end 26 is configured and sized to receive the shaft receiving member 18, the first and second lateral faces 32 and 34 are configured and sized to respectively receive the first and second preformed skins 20 and 22.

[0060] At least one of the first and second faces 26, 28 may include cavities 36. In the example shown here, it is the first face 32 which includes the cavities 36. As will easily be understood by one skilled in the art, the cavities 36 are advantageously provided on the face that is on the reverse side of the blade, i.e. the side less used for forceful shots by the hockey player.

[0061] The shaft receiving member 18 is shown including upper and lower portions 38 and 40 and first and second opposite lateral sides 42 and 44.

[0062] The upper portion 38 is configured and sized to be conventionally mounted to the hollow shaft 12.

[0063] Preferably, the upper portion 38 is smaller in dimension than the lower portion 40 such that lower portion 40 forms a shoulder 46. The hollow shaft 12 has a lower section 48 that is mountable to the upper portion 38 of the shaft receiving member.

[0064] The lower portion 40 is configured and sized to be mounted to the proximate end 20 of the core 16 as will be described hereinafter.

[0065] More specifically, the proximate end 26 of the core 16 includes a recess 54 corresponding to the shape of the lower portion 40 of the shaft receiving member 18 so as to be engaged thereby in a complementary fit.

[0066] Keeping the above in mind, a hockey stick blade 10 in accordance with a preferred embodiment of the present invention is made as follows.

[0067] The blade 10 is constructed by first making a preformed core 16 of the type described above and having a size that is smaller than that of the finished blade 10.

[0068] Preferably, this preformed core 16 is made of a single piece of wear-resistant material such as plastic. It is advantageous to use materials that are both strong enough to withstand the impact of a hockey puck and the like yet, light enough so that the user may easily manipulate the stick. Furthermore, as illustrated in the appended Figures, the bottom edge portion 30 or the core 16 may be in contact with the playing surface when the stick is used, hence the use of wear resistant material to manufacture the core 16.

[0069] In a preferred embodiment, the core 16 is made of thermosetting plastic reinforced with high modulus fibres such as glass, carbon or kevlar fibres. Conventionally, some blades 10 are curved such as those mounted to ice-hockey sticks and hence, have a concave or puck-hitting side. In this respect, it may be convenient to make the core 16 with a corresponding curvature. Conversely, the core may be made straight and curved during the skins gluing steps described hereinbelow.

[0070] As aforementioned, at least one of the first and second faces 26, 28 may include cavities 36. In this way, the core 16 will be made using the least material possible and hence, will have the minimum possible impact on the overall weight of the blade 10.

[0071] The shaft receiving member 18 may be made out of the same wear-resistant material as core 16, out of wood or out of any other suitable material. The shaft receiving member 18 is then mounted to the core 16. Specifically, an adhesive is provided between the lower portion 40 of the member 18 and the complementary recess 54 of the core proximate end 26. In this way, the first face 32 of core 16 and the first side 42 of member 18 are in the same lateral plane (hereinafter “first lateral plane”) while the second face 28 of core 16 and the second side 44 of member 18 are in the same lateral plane (hereinafter “second lateral plane”). The adhesive may be for example an epoxy-based adhesive, a vinyl-ester-based adhesive, a polyurethane-based adhesive or a metacrylate-based adhesive, when the core 16 is made of thermosetting plastic and the shaft receiving member 18 is made of wood. Of course, other suitable ways of mounting the shaft receiving member 18 to the core 16 may also be contemplated.

[0072] One skilled in the art will understand that the core 16 and the shaft receiving member 18 could be made of the same material and hence could be a single piece.

[0073] The first and second preformed skins 20, 22 may be made by a variety of known ways. Preferably and with reference to FIG. 5, the preformed skins 20, 22 are pre-cut out of a sheet of material 56 which will be described in details hereinafter. Skins 20, 22 may be cut by a variety of ways known in the art such as with a die cutter.

[0074] With particular reference to FIGS. 1, 2 and 3, the first skin 20 is mounted to both the first face 32 of core 16 and to the first side 42 of member 18 while the second skin 22 is mounted to the second face 34 of core 16 and the second side 44 of member 18. Preferably skins 20 and 22 are mounted to the core 16 and to the member 18 via an adhesive applied to their respective inner sides 58. The adhesive may be an epoxy-based adhesive, a vinyl-ester-based adhesive, a polyurethane-based adhesive or a metacrylate-based adhesive, for example. In this way, the shaft receiving member 18 is securely mounted to the core 16 both by the adhesive provided between its lower portion 40 and the recess 54 of the core 16 and by the skins 20 and 22.

[0075] With reference to FIGS. 3, it is to be noted that the core is so dimensioned in height that when the first and second skins 20, 22 are mounted to the first and second faces 32, 34 as explained above, the skins 20, 22 meet over the tapered top edge portion 28. Specifically, the top parts 60 of the skins 20, 22 meet and adhere to one another via an adhesive such as that used to attach the skins 20, 22 to the core 16 and to member 18. This is an advantage since it provides a blade 10 having a top portion that is very thin which is a desired feature in hockey stick blades.

[0076] The top edges 62 of the skins 20, 22 form the top edge 64 of the blade 10; the bottom edges 66 of skins 20, 22 and the bottom edge 30 of the core 16 form the bottom edge 68 of the blade ; and the distal end 24 of the core 16, and the distal ends 70 of the skins 20, 22 form the distal end 72 of blade 10.

[0077] Therefore, the core 16 is advantageously so dimensioned that the shape of the blade 10 is defined by the shape of the first and second preformed skins 20, 22. Hence, the same core 16 can be used for a variety of blades shaped in different manners. A particular blade shape may be selected on the basis of the shape of the skins 20, 22. Hence, the skins 20, 22 as preformed according to the desired final shape of the blade 10.

[0078] As shown in FIG. 1, the length of the core 16 and the blade 10 may be substantially similar. However, the height of core 16 is smaller than that of the blade. As discussed hereinabove, the top edge portion 28 of the core 16 is tapered to yield a pointed top edge. This is an advantageous feature since it allows the top skins 20 and 22 to meet without creating a significative void in the top edge portion thereof. Indeed, such a void would either fill with adhesive, which would unnecessarily make the blade heavier, or would stay void and create a frail spot in the blade.

[0079] The skins 20, 22 may be made of a variety of materials. In the preferred embodiment of FIGS. 1 to 4, the skins 20 and 22 are made of high modulus fibre such as glass, carbon and/or kevlar fibres in a rigid binding resin. The skins 20 and 22 could also be made of thin strip reinforcement of parallel axial high modulus fibres in a matrix of thermoset resin, for example. Of course other suitable materials for making skins 20, 22 such as, for example, high quality wood veneer and acrylonitrile/butadiene/styrene plastic (ABS plastic) may also be used.

[0080] Turning now more specifically to FIG. 4 of the appended drawings, the skins 20, 22 are also configured to receive a protective layer 74 thereon. This protective layer 74 may cover the whole blade 10 with the exception of the distal end 72 if so desired. The protective layer 74 may advantageously be made of a reinforcing high modulus light weight fabric. Preferably, the protective layer 74 is made of fiberglass woven textile within a matrix of plastic material.

[0081] Turning now briefly to FIG. 6 of the appended drawings, a blade 100 will be described. The major difference between the blade 100 and the blade 10 of FIGS. 1-5 concerns the skin 102 which is made of wood instead of the fibre making the skin 20 as discussed hereinabove. This illustrates that the two skins are not necessarily made of the same material.

[0082]FIG. 7, which is very similar to FIG. 4, illustrates a blade 200 where both the first and second skins 202 and 204 are made of wood veneer and are covered by a protective layer 206 advantageously made of a reinforcing high modulus light weight fabric.

[0083] With reference to FIG. 8, which illustrates, in a sectional view similar to that of FIG. 2, a blade 300 according to a fourth embodiment of the present invention, each of preformed skins 302 and 304 includes superimposed outer and inner layers. More specifically, each skin 302 and 304 is provided with respective inner wood veneer layers 306 and 308 and outer fibre layers 310 and 312. As previously mentioned, other types of materials can be used to make the layers. Outer and inner layers are advantageously mounted to the core 16 by means of an adhesive such as for example an epoxy-based adhesive, a vinyl-ester-based adhesive, a polyurethane-based adhesive or a metacrylate-based adhesive.

[0084] It will be appreciated to one skilled in the art that the various blades 10, 100, 200 and 300 illustrated in FIGS. 1 to 8 and described hereinabove, are all provided with a shaft receiving member that is so configured and sized to conventionally mount the blade to a hollow shaft.

[0085] On the other hand, FIG. 9 of the appended drawings illustrates a hockey stick 400 provided with a blade 402 manufactured according to an aspect of the present invention and integrally mounted to the shaft 404 of the hockey stick.

[0086] As will be understood by one skilled in the art, the blade end of the shaft 404 is shaped as the lower portion 40 of the member 18 (see FIG. 1) to be mounted to the recess 54 of the core 16. The two skins 406 (only one shown) are then secured to the core 16 and to the blade end of the shaft 404.

[0087] It will therefore be understood that the term “shaft” used herein and in the appended claims should be construed as meaning an actual shaft 404 as shown in FIG. 9 or a shaft receiving member 18 as illustrated in FIG. 1 or any variation thereof.

[0088] It is also within the scope of the present invention to provide a blade core assembly (see FIG. 1) which includes the preformed core 16 and the shaft receiving member 18 which are pre-assembled.

[0089] It is to be understood that even though the appended drawings illustrate regular player's hockey stick, the present invention could be used to construct a goalkeeper hockey stick. The terms “hockey stick” and “blade” being generically used herein.

[0090] It is to be understood that the invention is not limited in its application to the details of construction and parts illustrated in the accompanying drawings and described hereinabove. The invention is capable of other embodiments and of being practised in various ways. It is also to be understood that the phraseology or terminology used herein is for the purpose of description and not limitation. Hence, although the present invention has been described hereinabove by way of preferred embodiments thereof, it can be modified, without departing from the spirit, scope and nature of the subject invention as defined in the appended claims. 

What is claimed is:
 1. A preformed core for a blade of a hockey stick or like game stick, said stick including a shaft, said core comprising: distal and proximate ends, said proximate end being configured and sized to receive the shaft; top and bottom edge portions, said top edge portion being tapered; and first and second opposite lateral faces, said first and second lateral faces being configured and sized to respectively receive first and second preformed skins; wherein said core is so dimensioned that the shape of the blade is defined by the shape of the first and second preformed skins.
 2. A preformed core according to claim 1, wherein said core is made of a single piece of wear-resistant material.
 3. A preformed core according to claim 2, wherein said core includes plastic material.
 4. A preformed core according to claim 3, wherein the core is made of thermosetting plastic reinforced with high modulus fibres.
 5. A preformed core according to claim 1, wherein at least one of said first and second faces includes cavities.
 6. A preformed core according to claim 1, wherein said proximate end includes a recess configured and sized to receive the shaft.
 7. A preformed core according to claim 1, wherein when the first and second preformed skins are mounted to said first and second opposite lateral faces, said core is so dimensioned so as to allow the first and second preformed skins to meet over said tapered top edge portion of the core.
 8. A blade core assembly for a blade of a hockey stick or like game stick, said stick including a shaft, said core comprising: a core including: distal and proximate ends; top and bottom edge portions, said top edge portion being tapered; and first and second opposite lateral faces; and a shaft receiving member including: upper and lower portions, said lower portion being mountable to said proximate end of said core, said upper portion configured and sized to receive the shaft; first and second opposite lateral sides; wherein when said shaft receiving member is mounted to said core, a) said first lateral face of said core and said first lateral side of said shaft receiving member are in the same first plane, b) said second lateral face of said core and said second lateral side of said shaft receiving member are in the same second plane; c) said first and second planes are configured and sized to respectively receive fist and second preformed skins, and d) said core is so dimensioned that the shape of the blade is defined by the shape of the first and second preformed skins.
 9. A blade to be mounted to a shaft of a hockey stick or like game stick, said blade comprising: a preformed core having distal and proximate ends, top and bottom edge portions and first and second opposite lateral faces; said top edge portion being tapered; a shaft receiving member having lower and upper portions and first and second lateral sides; said lower portion being mounted to said proximate end of said core, said upper portion being so configured and sized as to receive the shaft; first preformed skin mounted to both said first lateral face of said core and said first lateral side of said shaft receiving member; and second preformed skin mounted to both said second lateral face of said core and said second lateral side of said shaft receiving member; wherein said preformed skins define the shape of the blade.
 10. A blade according to claim 9, wherein said core is made of a single piece of wear-resistant material.
 11. A blade according to claim 10 wherein said core is made of plastic material.
 12. A blade according to claim 11, wherein said core is made of thermosetting plastic reinforced with high modulus fibres.
 13. A blade according to claim 9, wherein at least one of said first and second opposite lateral faces of said core includes cavities.
 14. A blade according to claim 9, wherein said proximate end of said core includes a recess configured and sized to receive said lower portion of said shaft receiving member.
 15. A blade according to claim 9, wherein at least one of said preformed skins includes of wood.
 16. A blade according to claim 9, wherein each of said preformed skins includes outer and inner superimposed layers of material.
 17. A blade according to claim 16, wherein said outer layer includes fibre and the inner layer includes wood .
 18. A blade according to claim 17, wherein said fibre are selected from the group consisting of glass fibres, carbon fibres and kevlar fibres.
 19. A blade according to claim 9, wherein said preformed skins are configured to receive a protective layer thereon.
 20. A blade according to claim 19, wherein said protective layer includes high modulus light weight fabric.
 21. A blade according to claim 20, wherein said high modulus light weight fabric includes fibre selected from the group consisting of glass fibres, carbon fibres and kevlar fibres.
 22. A hockey stick or like game stick, said stick comprising: a blade including: a preformed core having distal and proximate ends, top and bottom edge portions and first and second opposite lateral faces; said top edge portion being tapered, a shaft receiving member having lower and upper portions and first and second lateral sides, said lower portion being mounted to said proximate end of said core; and first preformed skin mounted to both said first lateral face of said core and said first lateral side of said shaft receiving member; and second preformed skin mounted to both said second lateral face of said core and said second lateral side of said shaft receiving member; wherein said preformed skins define the shape of the blade. and a shaft having a lower section mounted to said upper portion of said shaft receiving member.
 23. A hockey stick as recited in claim 22, wherein sadi shaft receiving member and said shaft are integrally formed.
 24. A method of making a blade to be mounted to a shaft of a hockey stick or like game stick, said method comprising the steps of: (a) making a preformed core for the blade, said core having a size that is smaller than that of the blade, said core including distal and proximate ends, top and bottom edge portions, and first and second opposite lateral faces; (b) making a shaft receiving portion including upper and lower portions and first and second opposite lateral sides; (c) mounting said lower portion of said shaft receiving member to said proximate end of said core; (d) making first and second preformed skins; (e) mounting said first preformed skin to said first lateral face of said core and to said first lateral side of said shaft receiving member and mounting said second skin to said second lateral face of said core and to said second lateral side of said shaft receiving member, wherein said first and second preformed skin define the final shape of the blade.
 25. A method according to claim 24, wherein each said first and second skins include outer and inner layers, said method including the substep of mounting said outer layers to respective inner layers.
 26. A method according to claim 24, further including the step of mounting a protective layer to said first and second preformed skins. 